Input Shaft: Notes
WARNING: This page is about a different car, the 2009 Volkswagen Rabbit, 2008 Volkswagen Rabbit, 2007 Volkswagen Rabbit, and 2006 Volkswagen Rabbit. However, it is still accessible from the selected car via links, so may be relevant.
Special tools and workshop equipment required
- Punch VW 407
- Thrust Pad VW 447 H
- Thrust Disc VW 412
- Tube Split VW 422
- Thrust Plate VW 401
- Thrust Plate VW 402
- Punch VW 408 A
- Tube 28 mm Dia 100 mm VW 421
- Thrust Tube VW 454
- Thrust Pad VW 447 i
- Thrust Pad VW 510
- Mounting Universal Joint 41-501
- Kukko Separating Tool 12-75 mm 17/1
- Inductive Heater VAS 6414
NOTE:
The input shaft must be adjusted because the position of the tapered roller bearing is affected when parts are replaced. Pay attention to the adjustment overview, refer to ADJUSTMENT OVERVIEW .
Replace both tapered roller bearings together.
Wearing safety gloves, warm the bearing inner races, the gears and the synchronizer hubs to approximately 100 °C (212 °F) using the VAS 6414 before installing them.
- Clutch Housing
- Outer Race/Tapered Roller Bearing
- Removing, refer to Removing the Outer Race/Tapered Roller Bearing .
- Installing, refer to Installing the Outer Race/Tapered Roller Bearing .
- Bearing Inner Race/Taper Roller Bearing
- Removing, refer to Removing the Bearing Inner Race/Taper Roller Bearing .
- Installing, refer to Installing the Bearing Inner Race/Taper Roller Bearing .
- Input Shaft
- Adjusting, refer to INPUT SHAFT, ADJUSTING .
- 3rd Gear
- Installed position: The shoulder faces 4th gear.
- Removing, refer to Removing the 3rd Gear .
- Installing, refer to Installing 3rd Gear .
- Lock Ring
- Always replace.
- 4th Gear
- Remove with the bearing inner race/tapered roller bearing and sleeve, refer to Removing the 4th Gear with the Tapered Roller Bearing and Sleeve .
- Installing, refer to Removing the 4th Gear with the Tapered Roller Bearing and Sleeve .
- The shoulder faces 3rd gear.
- Bearing Inner Race/Taper Roller Bearing
- Remove with 4th gear and sleeve, refer to Removing the 4th Gear with the Tapered Roller Bearing and Sleeve .
- Installing, refer to Installing the Bearing Inner Race/Taper Roller Bearing .
- Thrust Washer
- Outer Race/Tapered Roller Bearing
- Removing, refer to Removing the Outer Race/Tapered Roller Bearing .
- Installing, refer to Installing the Outer Race/Tapered Roller Bearing .
- Adjusting Shim
- Determining thickness, refer to INPUT SHAFT, ADJUSTING .
- Transmission Housing
- Sleeve
- For the needle bearing.
- Pressing off with 4th gear drive gear and tapered roller bearing inner race, refer to Removing the 4th Gear with the Tapered Roller Bearing and Sleeve .
- Installing, refer to Pressing on Sleeve for 5th Gear Needle Bearing .
- Mount before installing the thrust washer -item 9-.
- Needle Bearing
- For 5th gear.
- 5th Gear
- 5th Gear Synchronizer Ring
- With cast locking pieces, refer to 5TH GEAR, INSTALLING .
- Checking for wear, refer to 5TH GEAR, INSTALLING .
- Spring
- Installed position, refer to Assembling 5th Gear Locking Collar/Synchronizer Hub .
- Offset springs are used as of transmission build date 05 November 2001. Refer to Installation of Offset Springs -A- .
- Locking Pieces
- Quantity: 3
- Installed position, refer to 5th Gear Synchronizer .
- 5th Gear Synchronizer Hub
- Removing individually, refer to TRANSMISSION HOUSING COVER AND 5TH GEAR .
- Remove with the transmission housing. Refer to TRANSMISSION .
- 5th Gear Locking Collar
- Remove with the 5th gear synchronizer hub -item 19-.
- Plate Spring
- Installed position, refer to 5TH GEAR, INSTALLING .
- Bolt
- See -item 4- TRANSMISSION HOUSING AND 5TH GEAR COVER .
- Always replace.
- Holds in position with the adapter on the plate spring bolt head, refer to 5TH GEAR, INSTALLING .